Inductive power transfer control

ABSTRACT

An inductive power transfer (IPT) control method is disclosed for controlling the output of an IPT pick-up. The invention involves selectively shunting first and second diodes of a diode bridge to selectively rectify an AC current input for supply to a load, or recirculate the AC current to a resonant circuit coupled to the input of the controller. By controlling the proportion of each positive-negative cycle of the AC input which is rectified/recirculated, the output is regulated. Also disclosed is an IPT controller adapted to perform the method, an IPT pick-up incorporating the IPT controller, and an IPT system incorporating at least one such IPT pick-up.

REFERENCE TO RELATED APPLICATIONS

The present disclosure is a continuation of and claims benefit from U.S.patent application Ser. No. 15/150,385, filed May 9, 2016 which is basedon and claims benefit from U.S. patent application Ser. No. 13/816,630,filed Jun. 27, 2013 which is based on and claims benefit fromInternational Application Number PCT/NZ2011/000155 filed on Aug. 12,2011 which claims benefit from New Zealand application 587357 filed Aug.13, 2010, the entire contents of each of which are herein incorporatedby reference.

FIELD

This invention relates to the field of inductive power transfer. Moreparticularly, the invention relates to a method and circuit forcontrolling the inductive transfer of power to a decoupling pick-upwhich minimises transient disturbance to the track current.

BACKGROUND

In inductive power transfer (IPT) systems, power is transferredinductively between a primary conductive path or track supplied by analternating-current power supply (the power supply and track togetherforming a primary side of the IPT system), and one or more pick-upsinductively coupled with the track (forming the secondary side of thesystem).

The pick-up comprises a tuned or resonant circuit consisting of at leasta pick-up coil and a tuning capacitor. Two common pick-up topologies arethe series-tuned pick-up, in which the tuning capacitor is provided inseries with the pick-up coil, and the parallel-tuned pick-up, in whichthe tuning capacitor is provided in parallel with the pick-up coil. Thetuned circuit is typically electrically coupled to a control circuit(typically comprising a rectifier and a converter or regulator) toobtain the desired output to supply a load.

An alternative pick-up topology is known as the series-parallel tunedLCL (inductor-capacitor-inductor) pick-up, as shown by way of example inFIG. 1.

The series-parallel tuned LCL pick-up topology (hereinafter referred toas an LCL pick-up) is controlled with a slow switching (i.e. a switchingfrequency that is much less than the frequency of the IPT track)decoupling control method similar to a slow switching parallel-tunedpick-up. An issue with the slow switching topology is the transientinrush power drawn by the pick-up during normal power regulation. Inmultiple pick-up systems, each time the pick-up is switched on thetransient power inrush transiently reduces the track current. Thisdisturbance, if large, will limit the power flow to all other pick-upscoupled to the track. A control circuit topology for minimizing thistrack current transient disturbance using a parallel LC tuned pick-upcontroller was described by Boys, J. T.; Chen, C. I.; Covic, G. A.;“Controlling inrush currents in inductively coupled power systems,” The7th International Power Engineering Conference, 2005, Vol. 2, pp.1046-1051, Nov. 29, 2005-Dec. 2, 2005. However, this simple approachcannot be used in the LCL topology using existing design approachesbecause it requires a large DC inductor for continuous currentconduction in the switch mode circuit.

OBJECT OF THE INVENTION

It is therefore an object of the invention to provide a circuit and/ormethod which overcomes or ameliorates one or more disadvantages of theprior art, or alternatively to at least provide the public with a usefulchoice.

Further objects of the invention will become apparent from the followingdescription.

SUMMARY OF INVENTION

Accordingly in one aspect the invention may broadly be said to consistin a control method for an inductive power transfer (IPT) pick-upcomprising an AC input from a resonant circuit, the AC input beingelectrically coupled to a diode bridge adapted to rectify an AC currentfrom the AC input and supply a DC current to a DC output, the methodcomprising:

-   -   selectively shunting a first diode of the diode bridge to cause        the AC current to recirculate to the resonant circuit during a        positive period of the AC current; and    -   selectively shunting a second diode of the diode bridge to cause        the AC current to recirculate to the resonant circuit during a        negative period of the AC current;    -   wherein shunting of said first and second diodes is synchronised        with the AC current whereby a predetermined proportion of said        positive and negative periods of the AC current are rectified to        supply the DC current to the DC output, and a remaining        proportion of said positive and negative periods of the AC        current are recirculated to the resonant circuit.

Preferably said predetermined proportion occurs at the beginning of eachof the positive and negative periods of the AC current, wherein saidfirst or second diode, respectively, conducts the AC current following arespective zero-crossing of the AC current, and the remaining proportionof the positive or negative period is recirculated by shunting saidrespective first or second diode at an appropriate time. This mode ofoperation where the diode conducts first is referred to in this documentas Mode I.

Alliteratively said predetermined proportion occurs towards the end ofeach of the positive and negative periods of the AC current, whereinsaid first or second diode, respectively, is shunted upon a respectivezero-crossing of the AC current to initially recirculate the AC current,and the respective first or second diode is then un-shunted to conductthe AC current for the predetermined proportion of the positive ornegative period. This mode of operation where the diode is shunted firstis referred to in this document as Mode II.

Preferably the predetermined proportion of said positive and negativeperiods is proportional to a desired DC output, wherein the methodfurther comprises the steps of sensing the DC output and adjusting saidpredetermined proportion accordingly to obtain said desired DC output.

Preferably the method further comprises the step of slowly increasingsaid predetermined proportion to a required proportion upon switching onthe pick-up.

Preferably the method further comprises the step of slowly decreasingsaid predetermined proportion to zero upon switching off the pick-up.

Preferably said shunting is selectively controlled by selectivelyclosing first and second switches provided in parallel with respectivesaid first and second diodes.

Preferably said first and second switches are opened when said first orsecond diodes, respectively, are conducting.

Preferably the resonant circuit comprises a series-parallel tuned LCL(inductor-capacitor-inductor) pick-up circuit.

According to a second aspect, the invention may broadly be said toconsist in an IPT pick-up controller adapted to perform the methodaccording to the first aspect of the invention.

According to a third aspect, the invention may broadly be said toconsist in an inductive power transfer (IPT) pick-up controllercomprising:

-   -   an input for receiving an AC current from a resonant circuit;    -   an output for supplying a DC current to a load; and    -   a control circuit electrically coupling the input and the        output, the control circuit comprising a diode bridge, shunting        switches, and control means for selectively operating said        switches to shunt first and second diodes of said diode bridge        in synchrony with the AC current.

Preferably said control means is adapted to selectively shunt said firstand second diodes using said shunting switches, whereby respectivepredetermined proportions of positive and negative periods of the ACcurrent are rectified by the diode bridge and supplied to the output,and respective remaining proportions of the positive and negativeperiods of the AC current are recirculated to the resonant circuit.

Preferably said shunting switches comprise two switches, each of saidtwo switches being provided in parallel with respective said first andsecond diodes, wherein said first and second diodes have a common anode.

Alternatively said shunting switches may comprise two switches having acommon cathode, each provided in parallel with respective first andsecond diodes.

Preferably the switches comprise MOSFET transistors, wherein said firstand second diodes comprise body diodes of said MOSFET transistors.

Preferably said control means further includes sensing means forming afeedback loop to sense the output and adjust said predeterminedproportions to obtain a desired output.

Preferably said control means further includes a zero-crossing detectorto synchronise shunting of the first and second diodes in relation tothe zero-crossing of the AC current.

According to a fourth aspect, the invention may broadly be said toconsist in an IPT pick-up adapted to perform the method according to thefirst aspect of the invention, and/or comprising an IPT pick-upcontroller according to the second or third aspects of the invention.

Preferably said resonant circuit comprises a series-parallel tuned LCL(inductor-capacitor-inductor) resonant circuit.

According to a fifth aspect, the invention may broadly be said toconsist in an IPT system comprising at least one pick-up controlleraccording to the second or third aspects of the invention, and/or atleast one IPT pick-up according to the fourth aspect of the invention.

Further aspects of the invention, which should be considered in all itsnovel aspects, will become apparent from the following description.

DRAWING DESCRIPTION

A number of embodiments of the invention will now be described by way ofexample with reference to the drawings in which:

FIG. 1 is a circuit diagram of a series-parallel tuned LCL pick-upaccording to the prior art;

FIG. 2 is a circuit diagram of a series-parallel tuned LCL pick-upaccording to the present invention;

FIG. 3 shows simulated waveforms of an example of a circuit as showngenerally in FIG. 2, when operating in a first mode (being Mode I);

FIG. 4 shows simulated waveforms of the same example circuit whenoperating in a second mode (being Mode II);

FIG. 6 is a graph showing the normalised output current versus switchconduction interval for various V_(DC)/V_(oc) ratios for the sameexample circuit when operating in Mode I;

FIG. 6 is a graph showing the normalised output current versus switchconduction interval for various V_(DC)/V_(oc) ratios for the sameexample circuit when operating in Mode II;

FIG. 7 is a graph showing the normalised reflected reactive impedanceversus the switch conduction interval for various V_(DC)/V_(oc) ratiosfor the same example circuit when operating in Mode I;

FIG. 8 is a graph showing the normalised reflected reactive impedanceversus the switch conduction interval for various V_(DC)/V_(oc) ratiosfor the same example circuit when operating in Mode II; and

FIG. 9 shows actual waveforms of an example pick-up circuit according tothe present invention, using the circuit of FIG. 2 and operating underMode I at half rated load.

FIGS. 10(a), 10(b) and 10(c) show actual waveforms of an example pick-upcircuit according to the present invention, using the circuit of FIG. 2and operating in Mode I under various load conditions (⅓, ⅔ and ratedload).

FIG. 11 shows efficiency measurements of the pick-up circuit accordingto the present invention, using the circuit of FIG. 2 operating in ModeI across the load range.

DETAILED DESCRIPTION OF THE DRAWINGS

Throughout the description like reference numerals will be used to referto like features in different embodiments.

The present invention provides a control method and/or circuit for aseries-parallel tuned LCL pick-up which achieves both rectification andpower regulation. The invention is referred to generally in thisdocument as “circulating current control”. It operates in a similarfashion to a traditional SCR controlled rectifier where the switches arecontrolled to switch synchronously with the IPT track frequency. Theduty cycle is controlled to ensure a smooth average output power isachieved, capable of providing a smooth power transition between a fullyon and a fully off state or behaving as a fast switching (i.e. theswitching frequency is similar to, or in synchronism with, the IPT trackfrequency) control topology.

Referring first to the prior art pick-up shown in FIG. 1, thecharacteristic impedance X is given by:

$\begin{matrix}{X = {{{\omega\; L_{2}} - \frac{1}{\omega\; C_{series}}} = \frac{1}{\omega\; C_{2}}}} & (1)\end{matrix}$

Here, C_(series) is used to increase the output current capability. Thevalues of L₃ and C₃ are chosen so that the rectifier operates undercontinuous conduction for maximum output power, and are also designed toaccommodate the extra inductance, introduced by the non-linear effect ofthe rectifier, to minimize the current in L₂. The slow switchingcontroller for the LCL network operates in a similar manner to aparallel-tuned circuit, except that whereas in a parallel LC circuit theresonance collapses when the switch is closed, here in the LCL topologythe full resonant current still circulates through C₂, L₃, C₃ and therectifier. The real part of the reflected impedance Z_(r) of the LCLnetwork onto L₁ is expressed by:

$\begin{matrix}{Z_{r} = {{\frac{8}{\pi^{2}}\left( \frac{\omega\; M}{X} \right)^{2}{R_{DC}\left( {1 - D} \right)}^{2}} = {\frac{2\sqrt{2}}{\pi}\frac{\omega^{2}M^{2}}{X}\frac{V_{DC}}{V_{oc}}\left( {1 - D} \right)^{2}}}} & (2)\end{matrix}$

V_(DC) is the regulated DC output voltage of the circuit as shown inFIG. 2, and V_(oc) is the open circuit voltage of the pick-up coil.

As shown in equation 2, the reflected impedance, which corresponds tothe power drawn by the pick-up, back to the primary track is directlycontrolled by the switch duty cycle D. As the value of D changes from 1(i.e. switch S in FIG. 1 remains closed) to 0 (i.e. switch S remainsopen) or vice versa, the power drawn from the power supply changes. Inpractice, however, the primary track current will also transientlydecrease and temporarily affect the power transfer to other pick-ups onthe same track.

The proposed circulating current control circuit, as shown by way ofexample in FIG. 2, preferably comprises four diodes (D₁, D₂, D₃, and D₄)in a diode bridge rectifier configuration, with switches (S₁ and S₂)respectively shunting the first and second diodes (D₁ and D₂) such thatclosing the switch S₁ or S₂ causes current to recirculate in the ACresonant circuit during the positive or negative period of I_(L3),respectively. In practice, however, the shunted diodes of the diodebridge may comprise the body diodes of MOSFET transistors forming theswitches S₁ and S₂.

The control circuit couples an AC current input to a DC output. In FIG.2, the DC output is shown connected to a load, R_(DC). The controlcircuit may also comprise a reservoir or smoothing capacitor C_(DC)across the output/load, as shown.

The switches S₁ and S₂ are used to clamp part of the resonant current inL₃ (I_(L3)). V_(g1) and V_(g2) are the pulse-width modulated (PWM) gatesignals which drive S₁ and S₂, and are synchronized with I_(L3) asdescribed in further detail below, using a zero-crossing detector, forexample. The terms “synchronised”, “synchrony” and the like as usedherein are intended to refer to carefully controlling the time at whichswitching occurs, with respect to the AC current input. The phase anglebetween the AC input and switching is not necessarily simultaneous with,for example, a zero crossing of the AC current input so that switchingoccurs at precisely the same time every cycle, but is controlled and ifnecessary varied with respect to the zero crossing so as to regulate orotherwise control the output of the IPT pick-up controller.

For one skilled in the art it is clear that a similar control outputcould be achieved if the two control switches were moved to shunt thetop two diodes rather than the bottom two diodes of the rectifier. Inthis case switches S₃ and S₄ can operated to shunt D₃ and D₄ and canalso be operated with two possible modes of control (as discussedherein) to achieve a similar result. In this configuration, gate drivesignals discussed herein for S₁ would be used to drive S₄ while the gatedrive for S₂ would be used to drive S₃. Other such variations ormodifications of the circuit are possible with departing from the scopeof the invention.

The pick-up controller circuit of the present invention may be operatedin two ways. The first mode of operation is to allow D₃ or D₄ to conductat the beginning of the positive period or the negative period,respectively, of I_(L3) and then turn on S₁ or S₂ to clamp part ofI_(L3) to regulate output power. As mentioned previously in thisdocument, this operation mode is referred to as Mode I.

The second mode of operation is to keep S₁ or S₂ conducting at thebeginning of the positive or the negative period of I_(L3) and then turnoff the switch to allow part of I_(L3) to be transferred to the load. Asmentioned previously in this document, this operation mode is referredto as Mode II.

The switches S₁ and S₂ may be controlled using any suitable controlmeans, such as a microcontroller and/or logic circuit, for example. Thecontrol means may also include sensing means (to sense the pick-upoutput current, voltage and/or power) and a feedback loop to allowcontrol and/or regulation of the pick-up circuit output. Variousdifferent control means may thus be used without departing from thescope of the invention. Implementation of a suitable control means isconsidered to be within the capabilities of a technician skilled in theart.

The operation of Mode I is illustrated in the waveforms of FIG. 3.

The rising edge of the gate signals and thus the duty cycle of V_(g1)and V_(g2) are controlled with a phase delay θ₁ (called the diodeconduction interval) referenced to the respective negative-to-positiveand positive-to-negative zero-crossings of I_(L3) as shown in FIG. 3.

At t₀, current I_(L3) has just turned positive. With the first switch S₁being at the default off state, the diode D₃ starts to conduct. Thecurrent I_(L3) is then transferred to the load R_(DC) via D₃ and thebody diode D₂ of S₂ for a predetermined proportion of the positiveperiod of the current I_(L3). The instantaneous output voltage of theLCL network is equal to +V_(DC).

At t₁ where the diode conduction interval θ₁ is reached, S₁ is turned onand I_(L3) circulates through S₁ and the body diode D₂ of S₂ to stoppower being transferred to the load R_(DC) for the remaining proportionof the positive period of the current I_(L3). Instead, the current isrecirculated to the resonant circuit.

At t₂=T/2, I_(L3) turns negative so that D₄ conducts for a predeterminedproportion of the negative period of I_(L3) and the circuit is completedwith the first diode D₁, the body diode of S₁. While the S₁ body diodeD₁ is conducting, S₁ can be turned off with zero current. Theinstantaneous value of V_(LCL)=−V_(DC). The power transferred to theload R_(DC) is identical in the second (negative) half cycle providedthe phase delay (the diode conduction interval) θ₁ is maintainedconstant.

At t₃, the gate signal V_(g2) turns on S₂ to keep I_(L3) circulatingthrough S₂ and the body diode D₁ of S₁ for the remaining proportion ofthe negative period of I_(L3), recirculating the current to the resonantcircuit. As I_(L3) circulates through the body diode of S₁, the gatesignal V_(g1) can turn S₁ off anytime between T/2 and T.

With switches S₁ and S₂ thus controlled such that they are synchronisedwith I_(L3), the output current (I_(D3)+I_(D4)) is a rectified, chopped(near) sine wave. By controlling the diode conduction interval θ₁, orequivalently the switch conduction interval θ₂ (here θ₂=T/2−θ₁) theaverage output current is directly and smoothly controlled. θ₁ can bevaried from 0 to π.

Mode II operation is illustrated in FIG. 4. It operates in a verysimilar fashion to Mode I but with a different switching sequence. Thefalling edge of the gate signals and thus the duty cycle of V_(g1) andV_(g2) are controlled with a switch conduction interval θ₂ referenced toI_(L3) as shown in FIG. 4.

Before current I_(L3) turns positive at t₀, the body diode D₁ of switchS₁ is already turned on with I_(L3) flowing in the negative direction.Thus, turning on S₁ during the negative period of I_(L3) will result inzero current/zero voltage switching.

At t₀, I_(L3) turns positive. With S₁ being turned on, I_(L3) is forcedto recirculate through S₁ and the second diode D₂, the body diode of S₂,to the resonant circuit. No power is transferred to the load R_(DC) forthis proportion of the positive period of I_(L3) (equivalent to the“remaining proportion” of the positive period in Mode I operation).

At t₁ where the switch conduction interval θ₂ is reached, S₁ is turnedoff and I_(L3) circulates through D₃ and the body diode D₂ of switch S₂to transfer power to the load for a predetermined proportion of thepositive period of I_(L3). During this proportion, the instantaneous LCLoutput voltage V_(LCL) is +V_(DC). Anytime between t₀ to T/2, V_(g2)could turn S₂ on with zero current/zero voltage switching like S₁.

At t₂=T/2, I_(L3) turns negative so that D₃ turns off softly and I_(L3)recirculates through S₂ and the body diode of S₁ to the resonantcircuit.

At t₃, the gate signal V_(g2) turns off S₂ to allow I_(L3) to transferpower to the load through D₄ for a predetermined proportion of thenegative period of I_(L3). The instantaneous value of the LCL outputvoltage V_(LCL) is −V_(DC).

With the switch conduction interval θ₂ and diode conduction interval θ₁maintained constant, the power transferred to the output in eachhalf-cycle is identical.

By controlling the switch conduction interval θ₂ of both switches S₁ andS₂ synchronously with I_(L3), the output power is directly and smoothlycontrolled. This provides the capability for regulating the output powerwith variable mutual coupling in comparison to the traditional slowswitching control topology. The present invention also allows a smoothtransition between a fully on and fully off state of the LCL pick-up inslow switching applications by ramping up and down the duty cycle fromzero power to full power, thereby minimizing track current transientdisturbance.

Derivation of a theoretical expression for describing the DC outputcurrent with respect to either the diode conduction interval θ₁ orswitch conduction interval θ₂ is impractical.

Instead, a numerical solution is presented below. The circulatingcurrent controller for both suggested operation modes are simulated withvarious ratios of V_(DC)/V_(oc). The normalized output current fordifferent V_(DC)/V_(oc) ratios are shown in FIG. 5 for the Mode Ioperation. Here I_(dc) _(_) _(max) is the ideal maximum output currentof an LCL pick-up and is given by:

$\begin{matrix}{I_{dc\_ max} = \frac{2{\sqrt{2} \cdot V_{oc}}}{\pi\; X}} & (3)\end{matrix}$

The SPICE simulation results shown in FIG. 5 demonstrate that therelationship between the output current and the switch conductioninterval θ₂ is not affected by V_(DC)/V_(oc). This is due to the outputcurrent source characteristic of the LCL network. The ideal output DCcurrent of the LCL network is a rectified sine wave with zero switchconduction interval. With harmonics introduced into the output currentby the rectifier, this causes the output current to be slightlydistorted from an ideal sine wave. Thus, with a switch conductioninterval of zero, the normalized maximum output current is around 0.95instead of 1. With the switch conduction interval θ₂ controlled from 0°to 180° the output power can be precisely controlled and regulatedaccording to the relationship shown in FIG. 5.

The simulation results shown in FIG. 5 (and the figures which follow)are for a particular example of a circuit according to the presentinvention, as generally shown in FIG. 2. For a different LCL design(i.e. different inductance and capacitance values), the profile of theoutput current and reflected impedance will be different.

Simulation results of normalized output current for variousV_(DC)/V_(oc) ratios in the Mode II operation are shown in FIG. 6.Similar to Mode I, the normalised DC output current with respect to theswitch conduction interval θ₂ is the same for various V_(DC)/V_(oc)ratios. However, the relationship between the output DC current and theswitch conduction interval θ₂ is completely different. Between 0° to 20°the output DC current increases with increasing switch conductioninterval instead of decreasing as in Mode I. Between 20° to 180°, the DCcurrent drops with increase of switch conduction interval. Comparingwith Mode I, the decay of DC current is a lot slower for Mode IIoperation. This is thought to be caused by the extra current harmonicsintroduced by the switching action. With Mode I operation, theintroduced harmonics circulate through the switches and L₃ instead ofcirculating to the load. Therefore, between switch conduction intervalof 0° to 20°, with the introduced current harmonics in I_(L3) theresultant output current is greater than when the switches are fullyoff, and a different overall output current behaviour is observedbetween these two operations.

With pick-up switch conduction interval θ₂ varying from 0° to 180° theoutput power is controlled but the phase of the LCL AC fundamentaloutput voltage is also varied relative to I_(L3). This introduces anextra Var load into the LCL network for both operation modes. This Varload reflects back onto the primary track causing the power supply to beslightly mistuned. Simulation results of the normalized reflectedreactive impedance for various ratios of V_(DC)/V_(oc) are shown inFIGS. 7 and 8 for Mode I and Mode II of operation, respectively.

In Mode I operation (as shown in FIG. 7), the reflected impedance swingsbetween an inductive and a capacitive load for different switchconduction intervals. When the switch conduction interval θ₁ ismaintained between 0° and 135°, the reflected load seen by the primarytrack is inductive which slightly increases the track inductance. Thishappens because the phase of V_(LCL) leads I_(L3). With an increase ofphase difference between V_(LCL) and I_(L3) the reflected inductive loadkeeps on increasing. This increase in the reflected inductive loadgradually slows down until the switch conduction interval θ₂ reachesaround 90° where it starts decreasing. This is because the magnitude ofV_(LCL) keeps decreasing with the increase in switch conduction intervalθ₂. Therefore, the increase in phase difference between V_(LCL) andI_(L3) becomes less dominant. When the switch conduction interval θ₂varies between 135° and 180° the reflected impedance to the primary iscapacitive, which slightly reduces the track inductance. This is becausethe combined impedance of L₃ and C₃ is normally less than X toaccommodate the inductance introduced by the rectifier. The amount ofreflected impedance back to the track is proportional to theV_(DC)/V_(oc) ratio.

Unlike Mode I operation, the reflected impedance during Mode IIoperation is purely capacitive, as shown in FIG. 8. This is due to thephase between V_(LCL) and I_(L3) are in the opposite way as to Mode I(i.e. here in Mode II V_(LCL) lags I_(L3)). The maximum reflectedreactive impedance occurs at the same conduction interval of 90° and itis proportional to the V_(DC)/V_(oc) ratio as it is under Mode Ioperation.

An example embodiment of the present invention is described below by wayof example. A 2.5 kW 50V implementation of the proposed circulatingcurrent duty cycle control pick-up was built and tested using acommercially-available Wampfler™ 10 kW IPT power supply, which also usesan LCL resonant network for an AGV (automated guided vehicle)application. However, the pick-up of the present invention may be usedwith any suitable power supply, as will be appreciated by those skilledin the art.

The pick-up parameters and the track inductance of this example arelisted in Table 1 below.

TABLE 1 I₁ 125 A M 3.56 μH V_(oc) 56 V L₁  26 μH f   20 kHz V_(DC) 50 VL₂ 100 μH P_(out)  2.5 kW X  1 Ω

An oscilloscope capture of the pick-up operating at half the rated poweris shown in FIG. 9 operating in Mode I. The top waveform is the currentin L₃ (I_(L3)), the second waveform is the LCL AC output voltage(V_(LCL)), while the third waveform is the total output current of D₃and D₄ (I_(D3)+I_(D4)). The last (bottom) waveform is the switch gatedriving signal V_(g1). This capture shows that the output voltage of theAC tuned network V_(LCL) is successfully controlled by controlling thediode conduction interval θ₁, relative to I_(L3).

FIG. 10 shows an oscilloscope capture of the pick-up operating in Mode Iat other loading conditions, without the switch gate driving waveformFIG. 10(a) shows operation at ⅓ rated load, FIG. 10(b) shows operationat ⅔rds rated load, and FIG. 10(c) shows operation at rated load.

The pick-up efficiency measurements under various loading conditions areshown in FIG. 11. As seen from FIG. 11, the example pick-up achieves anefficiency of 88% at full load and is still above 85% at half load. Thiscontroller operates at 50V and 50 A where high efficiency is difficultto achieve.

As discussed above, the circulating current duty cycle control method ofthe present invention reflects a variable reactive impedance dependingon the controlled switch conduction interval. With the presented systemparameters in Table 1, the maximum reflected reactive impedance of theprototype system can be calculated using FIGS. 7 and 8.

With Mode I operation the maximum reflected inductive load occurs with aswitch conduction interval of 80° as shown in FIG. 7. The maximumreflected capacitive load occurs at 180°, which corresponds with thepick-up being fully off. The calculated maximum reflected inductiveimpedance is 0.0415Ω, which corresponds to increasing the primary trackinductance by 0.33 μH. The Wampfler 10 kW primary power supply track istuned to 26 μH with a tolerance of +/−2 μH, so it would require 6pick-up controllers operating simultaneously at 80 degrees switchconduction interval to accumulate up to 2 μH. Since this example systemis not designed to carry more than 4 pick-ups at any one time to preventpower supply overloads, the reflected inductive load would not be anissue in this design. On the other hand, the maximum reflectedcapacitive impedance is −0.0726Ω, which corresponds to reducing theprimary track inductance by 0.577 μH. It would take up to 4 controllers,fully off, to exceed the −2 μH threshold.

With Mode II operation the reflected reactive impedance is purelycapacitive and the maximum reflected impedance occurs with an 80° switchconduction interval as discussed above. Using Table 1 and FIG. 8, themaximum reflected reactance is −0.151Ω, which corresponds to reducingthe primary track inductance by 1.202 μH. If more than 1 pick-up on thetrack switches at the same time, the detuning effect to the power supplywill exceed the 2 μH threshold. Thus, under this circumstance thecirculating current duty cycle control could be used as a transitionscheme between the pick-up controller being fully off and on in a slowswitching control method. With a sequential switching (i.e. interleavingswitching) control method, no more than 2 pick-ups could be switching onthe same track at the same time when operating in Mode II to avoidreflected reactance overloads in the power supply. However, a powersupply adopting an LCL resonant network topology has better tolerancefor its track inductance being less than its designed value, while onlyslightly compromising the maximum power rating of the power supply.Therefore, although the extra Var load introduced by the proposedcirculating current duty cycle controller slightly detunes the primarypower supply, in practice this VAR load can easily be handled by normalsystem parameter tolerances.

As described above, the method of the present invention would typicallybe implemented by control means which may comprise some form ofcomputing means or digital or mixed-signal computing device orprocessor, such as a microcontroller adapted to provide appropriate gatevoltages to switches S₁ and S₂, for example. Once programmed to performparticular functions pursuant to instructions from program software thatimplements the method of this invention, the computing device in effectbecome a special-purpose computing device particular to the method ofthis invention. The techniques necessary for this are well-known tothose skilled in the art of embedded systems.

Computer programs implementing the method of this invention may bedistributed to users on a distribution medium such as floppy disk,CD-ROM, or USB flash memory. From there, they may be copied to a harddisk, embedded solid-state memory, or a similar intermediate storagemedium. When the programs are to be run, they will be loaded either fromtheir distribution medium or their intermediate storage medium into theexecution memory of the computing means, configuring the computing meansto act in accordance with the method of the invention. All theseoperations are well-known to those skilled in the art of computersystems.

The term “computer-readable medium” encompasses distribution media,intermediate storage media, execution memory of a computer, and anyother medium or device capable of storing for later reading by acomputing device implementing the method of this invention.

Alternatively, the inventive method may be performed entirely inhardware, by a plurality of discrete electronic components and/or anapplication specific integrated circuit (ASIC), for example.

The invention, and in particular the control means, may therefore besaid to consist in a computer program adapted to perform the method ofthe invention, a computer-readable medium storing such a computerprogram, and/or a hardware system adapted to perform the above-describedmethod of the invention.

From the foregoing it will be seen that a pick-up control method and apick-up controller are provided which allows the regulation of outputpower in a slow-switching series-parallel tuned LCL pick-up topology.This regulation allows either or both of compensation for variations inthe mutual coupling between the pick-up and the primary track, andramping up/down between the pick-up output levels to minimize trackcurrent transient disturbance.

Unless the context clearly requires otherwise, throughout thedescription, the words “comprise”, “comprising”, and the like, are to beconstrued in an inclusive sense as opposed to an exclusive or exhaustivesense, that is to say, in the sense of “including, but not limited to”.

Although this invention has been described by way of example and withreference to possible embodiments thereof, it is to be understood thatmodifications or improvements may be made thereto without departing fromthe scope of the invention. The invention may also be said broadly toconsist in the parts, elements and features referred to or indicated inthe specification of the application, individually or collectively, inany or all combinations of two or more of said parts, elements orfeatures. Furthermore, where reference has been made to specificcomponents or integers of the invention having known equivalents, thensuch equivalents are herein incorporated as if individually set forth.

Any discussion of the prior art throughout the specification should inno way be considered as an admission that such prior art is widely knownor forms part of common general knowledge in the field.

The invention claimed is:
 1. A control method for an inductive powertransfer (IPT) pick-up, the pick-up comprising a resonant circuitproducing an AC input current, a rectifier circuit comprising a firstswitch operable to shunt a first diode of a diode bridge and a secondswitch operable to shunt a second diode of the diode bridge, and a DCoutput, wherein the AC input current is rectified to supply the DCoutput, the method comprising: selectively operating the switches toshunt first and second diodes of the diode bridge in synchrony with theAC current to provide the DC output.
 2. A The control method of claim 1further comprising: selectively operating the first switch to shunt thefirst diode of the diode bridge to cause the AC current to recirculateto the resonant circuit during a positive period of the AC current; andselectively operating the second switch to shunt the second diode of thediode bridge to cause the AC current to recirculate to the resonantcircuit during a negative period of the AC current; wherein shunting ofsaid first and second diodes is synchronised with the AC current wherebya predetermined proportion of said positive and negative periods of theAC current are rectified to supply the DC current to the DC output, anda remaining proportion of said positive and negative periods of the ACcurrent are recirculated to the resonant circuit.
 3. The control methodof claim 1, wherein the predetermined proportion occurs at a beginningof each of the positive and negative periods of the AC current, whereinsaid first or second diode, respectively, conducts the AC currentfollowing a respective zero-crossing of the AC current, and theremaining proportion of the positive or negative period is recirculatedby shunting said respective first or second diode at an appropriatetime.
 4. The control method of claim 1, wherein the predeterminedproportion occurs towards an end of each of the positive and negativeperiods of the AC current, wherein said first or second diode,respectively, is shunted upon a respective zero-crossing of the ACcurrent to initially recirculate the AC current, and the respectivefirst or second diode is then un-shunted to conduct the AC current forthe predetermined proportion of the positive or negative period.
 5. Thecontrol method of claim 1, wherein the predetermined proportion of saidpositive and negative periods is proportional to a desired DC output,wherein the method further comprises sensing the DC output and adjustingsaid predetermined proportion accordingly to obtain a desired DC output.6. The control method of claim 1, wherein the method further comprisesslowly increasing said predetermined proportion to a required proportionupon switching on the pick-up.
 7. The control method of claim 1, whereinthe method further comprises slowly decreasing said predeterminedproportion to zero upon switching off the pick-up.
 8. The control methodof claim 1, wherein said shunting is selectively controlled byselectively closing first and second switches provided in parallel withrespective said first and second diodes.
 9. The control method of claim8 wherein said first and second switches are opened when said first orsecond diodes, respectively, are conducting.
 10. An IPT pick-upcontroller adapted to perform the method according to claim
 1. 11. Thecontrol method of claim 1 further comprising selecting a required DCoutput, and ramping a duty cycle for the switches over a plurality ofcycles of the AC current to change the DC output toward the required DCoutput.
 12. An inductive power transfer (IPT) pick-up controllercomprising: an input for receiving an AC current from a resonantcircuit; an output for supplying a DC current to a load; and a controlcircuit electrically coupling the input and the output, the controlcircuit comprising a diode bridge, shunting switches, and a controllerfor selectively operating said switches to shunt first and second diodesof said diode bridge in synchrony with the AC current.
 13. The IPTpick-up controller of claim 12, wherein the controller is adapted toselectively shunt said first and second diodes using said shuntingswitches, whereby respective predetermined proportions of positive andnegative periods of the AC current are rectified by the diode bridge andsupplied to the output, and respective remaining proportions of thepositive and negative periods of the AC current are recirculated to theresonant circuit.
 14. The IPT pick-up controller of claim 12, whereinsaid shunting switches comprise two switches, said switches beingprovided in parallel with respective said first and second diodes,wherein said first and second diodes have a common anode.
 15. The IPTpick-up controller of claim 12, wherein the switches comprise MOSFETtransistors and said first and second diodes comprise body diodes ofsaid MOSFET transistors.
 16. The IPT pick-up controller of claim 13,wherein said controller further comprises a sensor forming a feedbackloop to sense the output and enabling adjustment of said predeterminedproportions to obtain a desired output.
 17. The IPT pick-up controllerof claim 12, wherein said controller further comprises a zero-crossingdetector to synchronise shunting of the first and second diodes inrelation to zero-crossing of the AC current.
 18. The IPT pick-upcontroller of claim 12, wherein the controller receives a required DCoutput, and ramps a duty cycle for the switches over a plurality ofcycles of the AC current to change the DC output toward the required DCoutput.